Sorting system for damaged product

ABSTRACT

A sorting system having a plurality of sorting assemblies where each sorting assembly has an image device that transmits an image of product to a controller that then actuates a robotic sorting device to remove damaged product through a suction tube based upon the transmitted image.

CROSS REFERENCE TO A RELATED APPLICATION:

This application is a continuation of U.S. patent application Ser. No.13/681,649 filed Nov. 20, 2012.

BACKGROUND OF THE INVENTION

This invention is directed toward a sorting system for damaged products,and more particularly to a sorting system that utilizes an image deviceand robotic sorting device to separate damaged product from non-damagedproduct.

Sorting systems are well known in the art. For some products,particularly those that require visual inspection, the systems requiremanual removal and are labor intensive. These systems also, in additionto being expensive to operate, are not as accurate as desired at anacceptable speed or require longer periods of sorting to increaseaccuracy. Accordingly, there is a need in the art for a system thataddresses these needs.

Therefore, an objective of the invention is to provide a sorting systemthat is automatic with a high level of accuracy.

Another objective of the invention is to provide a sorting system thatis less expensive and more efficient to operate.

These and other objectives will be apparent to one skilled in the artbased upon the following written description, drawings, and claims.

SUMMARY OF THE INVENTION

A sorting system having a plurality of sorting assemblies with eachsorting assembly having a conveyor mounted to a frame, a light sourceand image device mounted to the frame above the conveyor, a sortingdevice moveably mounted to the frame downstream of the image device,wherein the sorting device removes damaged product utilizing a suctiontube based on an image of the product sent to a controller that operatesrobotic arms of the sorting device.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a partial side view of a sorting system; and

FIG. 2 is a top plan view of a sorting system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the Figures, the sorting system 8 has a first sortingassembly 10 having a first conveyor 12 that receives product 14 ready tobe sorted. As an example only, the product used in this application isalmonds. But any non-agricultural or agricultural product such aswalnuts, pistachios, vegetables, peppers, tomatoes, onions, olives,fruits, and the like without departing from the scope of the invention.

Positioned near the loading end 16 of the first conveyor 12 and mountedto a frame 18 is a light source 20 which is of any type and preferablyincludes one or more LEDs. Positioned downstream from the light source20 and mounted to the frame 18 is an image device 22 for capturing alighted image device 22 for capturing a lighted image of the product 14on the first conveyor 12. The image device 22 is connected to acontroller 24, such as a CPU, and transmits an image of the product 14to the controller 24. The image device is of any type but preferably hasa spectrum of 250 such as a Resonon Hyperspectral camera or the like.

Downstream from the image device 22 is a sorting device 26. While thesorting device 26 is of any type and structure, preferred is a devicehaving one or more robotic arms 28 moveably mounted to a frame 30, acompressed air tube 32 or vacuum line/vacuum hose connected to a sourceof compressed air 34, a suction tube 36, and a moveable gate 38positioned at the opening of the suction tube 36. The robotic arms 28,controlled by actuators (not shown) the source of compressed air 34, andthe gate 38 are all connected to and controlled by the controller 24.

Positioned downstream from the sorting assembly 10 is a second sortingassembly 40 having a second conveyor 42, a light source 20, image device22, and a sorting device 26. Preferably, the second conveyor 42, whichis positioned adjacent a discharge end 44 of the first conveyor 12, liesin a horizontal plane below the horizontal plane of the first conveyor12. This permits product 14 from the first conveyor 12 to flip to anopposite or second side when sorted on the second conveyor 42.

In one embodiment a third sorting assembly 46 is associated with a thirdconveyor 48 that receives product sorted and removed from the first andsecond sorting assemblies 10, 40. The third sorting assembly 46, likethe first and second sorting assemblies 10, 40, has a light source 20,an image device 22, and a sorting device 26. A fourth image device 50 isassociated with the discard end of any of the conveyors 12, 42, or 48 orwith a fourth conveyor (not shown). The purpose of the fourth imagedevice is to record and verify that defective product 14 has beenremoved prior to packaging.

All of the conveyors 12, 42 and 48 have an encoder 54 associated witheach conveyor 12, 42, 48 and 52 that is also connected to the controller24. The encoder 54 sends information to the controller 24 with respectto the rotational speed of the respective conveyor and the distanceproduct 14 travels over time on the conveyor.

In operation, product 14 is delivered to the loading end 16 of the firstconveyor 12. As product 14 passes under the light source 20, the product14 is illuminated and the image device 22 captures information relatedto the product 14 that is transmitted to the controller 24. Thecontroller 24, via software, processes the transmitted information anddetects damaged product to be sorted based upon irregularities in size,shape, and/or color and the like. The controller 24 also identifies theposition of the damaged product based upon the time the information wascaptured and its location on the width (y-axis) of the conveyor 12 andinformation transmitted from the encoder 54 on the speed of the conveyor(x-axis).

As the damaged product approaches the sorting device 26, the controller24 determines the most efficient order, requiring the least amount oftime and movement, to pick up the damaged product. When the damagedproduct reaches the sorting device 26, the controller 24 sends a signalthat causes compressed air to be released from the source of compressedair 34 through the compressed air tube 32 and into the suction tube 36.The release of the compressed air through tubes 32 and 36 creates aventuri within the suction tube 36. Alternatively, the suction tube 36is connected to a vacuum.

Once the venturi is created, the controller 24 sends a signal actuatingthe robotic arms 28 to move over and down to the damaged product suchthat the product is held against an opening 56 in gate 38 by the venturicreated in the suction tube 36. Once held, the controller 24 opens thegate 38 and the damaged product is transported through tube 36 to ahopper or to the third conveyor 48. If a damaged product is missed, thisinformation is recorded for subsequent use on the second conveyor 42.

When the sorted product reaches the discharge end 44 of the firstconveyor 12, it is collected for packaging, or it falls to the secondconveyor 42 such that the product 14 is flipped to a second side. Theprocess is repeated on the second conveyor 42 wherein the product 14 isilluminated by the light source 20, an image is taken and transmitted tothe controller 24 by the image device 22 and product is sorted by thesorting device 26 based upon the transmitted information from the imagedevice 26 and the encoder 54. After sorting, product is transported tothe discharge end of the second conveyor 42 for packaging.

The third conveyor 48 receives damaged product from the first sortingassembly 10 and the second sorting assembly 40. The third sortingassembly 46 operates the same as the first and second sorting assemblies10, 40, wherein damaged product is removed and transported to a hoppervia the suction tube 38 and non-damaged product is returned to eitherthe first conveyor 12 or second conveyor 42 downstream the sortingdevice 26. Alternatively, the third sorting assembly 46 is programmed todetect non-damaged product such that non-damaged product is transportedto the first or second conveyor 12, 42 via the suction tube 36 whiledamaged product is transported on the third conveyor 48 to a hopper.

A fourth image device 26 is positioned at at least one discharge end ofthe conveyors, preferably the conveyor where non-damaged product ispresented for packaging. The purpose of positioning the image device 26at the end of the conveyor is to verify for a customer that the productbeing packaged meets a desired percentage of non-damaged product.

Accordingly, a sorting assembly has been disclosed that at the veryleast meets all of the stated objectives.

What is claimed is:
 1. A sorting system, comprising: a first conveyormounted to a frame; an image device mounted to the frame above the firstconveyor; a controller connected to the image device wherein thecontroller detects damaged product based upon information transmitted bythe image device; and a sorting device connected to the controllerwherein the controller moves the sorting device over and down to removedetected damaged product.
 2. The system of claim 1 wherein the sortingdevice has at least one robotic arm.
 3. The system of claim 1 whereinthe controller determines a most efficient order requiring a leastamount of time and movement in moving the sorting device to pick up thedamaged product.
 4. A sorting system, comprising: a first sortingassembly associated with a first conveyor; a second sorting assemblyassociated with a second conveyor and positioned downstream from thefirst conveyor; and a third sorting assembly associated with a thirdconveyor that receives damaged product from the first and the secondsorting assemblies.
 5. The system of claim 4 wherein the third sortingassembly removes non-damaged product from the third conveyor.
 6. Thesystem of claim 5 wherein the third sorting assembly transportsnon-damaged product to at least one of the first and the secondconveyors.